U.S. patent application number 12/573960 was filed with the patent office on 2010-02-04 for system and method for floor covering installation.
This patent application is currently assigned to INTERFACE, INC.. Invention is credited to Horace Eddie Bradley, JR., Susan F. Fezer, Keith N. Gray, Connie D. Hensler, Chung-Hsien Zah.
Application Number | 20100024329 12/573960 |
Document ID | / |
Family ID | 39591109 |
Filed Date | 2010-02-04 |
United States Patent
Application |
20100024329 |
Kind Code |
A1 |
Gray; Keith N. ; et
al. |
February 4, 2010 |
System and Method for Floor Covering Installation
Abstract
Connectors for joining adjacent modular floor covering units.
Embodiments of the connectors include a film and an adhesive layer
coated on one side of the film. The connectors can have a
conductive component that allows electrical continuity to be
maintained between adjacent tiles. In yet another embodiment, the
connectors can be equipped as radio frequency identification tags
by including radio frequency transponders. To install tiles using
the connectors, a first tile is placed on the floor and a connector
is positioned so that the adhesive layer faces upward and does not
contact the floor. The connector is typically positioned so that
only a portion of the adhesive layer adheres to the underside of
the tile, leaving the remainder of the connector extending from the
underside of the tile. One or more tiles are then positioned
adjacent the first tile so that a portion of the connector adheres
to the adjacent tiles. In this way, the connectors span adjacent
tile edges. The tiles are assembled on an underlying flooring
surface without the need to attach them to the floor surface.
Rather, the tiles are linked to each other with the connectors, so
that the tiles create a floor covering that "floats" on the
underlying floor surface. Additionally, the tiles need not be
installed directly on the floor surface. Rather, an underlayment,
such as a film or cushion or cushion composite, may be positioned
on the floor surface prior to the installation of tiles.
Inventors: |
Gray; Keith N.; (Marietta,
GA) ; Hensler; Connie D.; (Kennesaw, GA) ;
Zah; Chung-Hsien; (Kennesaw, GA) ; Fezer; Susan
F.; (Grantville, GA) ; Bradley, JR.; Horace
Eddie; (LaGrange, GA) |
Correspondence
Address: |
JOHN S. PRATT, ESQ;KILPATRICK STOCKTON, LLP
1100 PEACHTREE STREET, SUITE 2800
ATLANTA
GA
30309
US
|
Assignee: |
INTERFACE, INC.
Atlanta
GA
|
Family ID: |
39591109 |
Appl. No.: |
12/573960 |
Filed: |
October 6, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12056916 |
Mar 27, 2008 |
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12573960 |
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11018947 |
Dec 21, 2004 |
7464510 |
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12056916 |
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11251733 |
Oct 17, 2005 |
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11018947 |
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10638878 |
Aug 11, 2003 |
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11251733 |
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60920368 |
Mar 27, 2007 |
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60619340 |
Oct 15, 2004 |
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60403790 |
Aug 15, 2002 |
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60619340 |
Oct 15, 2004 |
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60690762 |
Jun 15, 2005 |
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Current U.S.
Class: |
52/220.1 ;
340/539.1; 340/604; 367/6; 52/309.1; 52/309.3; 52/403.1; 52/410;
52/578 |
Current CPC
Class: |
C09J 7/38 20180101; Y10T
428/23993 20150401; G01S 5/0027 20130101; E04F 2201/07 20130101;
E04F 15/02 20130101; B65H 2401/211 20130101; B65H 2701/1922
20130101; A47G 27/0475 20130101; A47G 27/0481 20130101; G01S 1/68
20130101; B65H 37/005 20130101; C09J 7/22 20180101; Y10T 156/109
20150115; C09J 2203/314 20130101; Y10T 428/16 20150115; Y10T
428/2848 20150115 |
Class at
Publication: |
52/220.1 ;
52/309.3; 52/403.1; 52/578; 52/309.1; 52/410; 340/539.1; 340/604;
367/6 |
International
Class: |
E04C 2/52 20060101
E04C002/52; E04C 2/20 20060101 E04C002/20; E04F 15/22 20060101
E04F015/22; E04C 2/30 20060101 E04C002/30; E04B 1/64 20060101
E04B001/64; G08B 1/08 20060101 G08B001/08; G08B 21/00 20060101
G08B021/00; H04B 1/59 20060101 H04B001/59 |
Claims
1. A connector for connecting modular tiles, each tile having an
underside, the connector comprising: a. a film; b. an adhesive on a
side of a film, wherein the adhesive is capable of forming a bond
with the undersides of the tiles so that, when a connector spans
adjacent edges of adjacent tiles so that the adhesive contacts the
undersides of the adjacent tiles, the adhesive prevents relative
movement between the adjacent tiles; and c. a conductive component
located on the film.
2. The connector of claim 1, wherein the conductive component is
located on the same side of the film as the layer of adhesive.
3. The connector of claim 1, wherein the conductive component
comprises copper.
4. A floorcovering installation comprising: a. a plurality of
tiles, each tile having an underside and edges, positioned on a
flooring surface; and b. connectors positioned to span adjacent
edges of at least some adjacent tiles, the connectors comprising:
i. a film; ii. an adhesive on a side of a film, wherein the
adhesive contacts the undersides of the at least some adjacent
tiles; and iii. a conductive component that contacts the undersides
of the at least some adjacent tiles.
5. A floorcovering installation comprising: a. an intermediate
substrate positioned on a flooring surface but not connected to the
flooring surface; b. a plurality of tiles, each tile having an
underside and edges, wherein the tiles are positioned on top of the
intermediate substrate but not connected to the intermediate
substrate; and c. connectors positioned to span adjacent edges of
at least some adjacent tiles, the connectors comprising: i. a
connector film; and ii. an adhesive on a side of a film, wherein
the adhesive contacts the undersides of the at least some adjacent
tiles.
6. The flooring system of claim 5, wherein the intermediate
substrate comprises an underlayment film.
7. The flooring system of claim 6, wherein the underlayment film
comprises polymeric material.
8. The flooring system of claim 6, wherein the underlayment film is
moisture impermeable.
9. The flooring system of claim 6, wherein the underlayment film
comprises a first side and a second side, each side having a
coefficient of friction, wherein the coefficient of friction of the
first side is greater than the coefficient of friction of the
second side.
10. The flooring system of claim 9, wherein the tiles are
positioned on top of the second side of the underlayment film.
11. The flooring system of claim 6, wherein the underlayment film
has a thickness between about 1/1000 inch and about 40/1000
inch.
12. The flooring system of claim 5, wherein the intermediate
substrate comprises a cushion.
13. The flooring system of claim 12, wherein the cushion comprises
at least one of foam, rubber, cork, woven fabric, nonwoven fabric,
or felted fabric.
14. The flooring system of claim 12, wherein the cushion is
moisture impermeable.
15. The flooring system of claim 5, wherein the intermediate
substrate comprises an underlayment film positioned on the flooring
surface and a cushion positioned on top of the underlayment
film.
16. The flooring system of claim 15, wherein at least one of the
underlayment film or the cushion is moisture impermeable.
17. The flooring system of claim 5, wherein the intermediate
substrate comprises a cushion composite comprising a first layer
attached to a second layer, wherein the first layer comprises a
cushion and the second layer is more rigid than the first
layer.
18. The flooring system of claim 17, wherein at least one gripping
component projects from a side of the second layer.
19. The flooring system of claim 18, wherein the flooring surface
comprises a carpeted surface and the cushion composite is
positioned on top of the carpeted surface so that the at least one
gripping component engages the carpeted surface.
20.-58. (canceled)
59. A method for establishing an array of radio frequency
transponders in known locations in a building, the method
comprising: (a) installing a planar array of regularly spaced radio
frequency transponders in a building, the method comprising: (i)
positioning a plurality of floorcovering tiles adjacent to one
another on a floor surface in the building, each tile having an
underside, edges and corners; and (i) positioning, under and
proximate regularly spaced, juxtaposed tile corners of the tiles,
radio frequency transponder assemblies comprising: (1) a film; (2)
a radio frequency transponder attached to the film; and (3) an
adhesive on a side of the film, wherein the adhesive contacts the
undersides of the tile corners; and (b) traversing the array of
regularly spaced radio frequency transponders with a radio
frequency reader and creating a data collection correlating
identifying information for the radio frequency transponders and
the locations of those radio frequency transponders within the
building.
60. A connector for connecting modular tiles, each tile having an
underside, the connector comprising: a. a film; b. an adhesive on a
side of a film, wherein the adhesive is capable of forming a bond
with the undersides of the tiles so that, when a connector spans
adjacent edges of adjacent tiles so that the adhesive contacts the
undersides of the adjacent tiles, the adhesive prevents relative
movement between the adjacent tiles; and c. a chemical sensor to
monitor moisture content of an underlying floor.
61. The method of claim 60, wherein the chemical sensor is
configured to provide information to a radio frequency
transponder.
62. The method of claim 60, wherein the chemical sensor is
configured to transmit a wireless signal if moisture content is
above a predetermined level.
63. A connector for connecting modular tiles, each tile having an
underside, the connector comprising: a. a film; b. an adhesive on a
side of a film, wherein the adhesive is capable of forming a bond
with the undersides of the tiles so that, when a connector spans
adjacent edges of adjacent tiles so that the adhesive contacts the
undersides of the adjacent tiles, the adhesive prevents relative
movement between the adjacent tiles; and c. a pressure sensor.
64. The method of claim 63, wherein the pressure sensor is
configured to provide information to a radio frequency
transponder.
65. The method of claim 63, wherein the pressure sensor is
configured to transmit a wireless signal if pressure is above a
predetermined level.
66. A connector for connecting modular tiles, each tile having an
underside, the connector comprising: a. a film; b. an adhesive on a
side of a film, wherein the adhesive is capable of forming a bond
with the undersides of the tiles so that, when a connector spans
adjacent edges of adjacent tiles so that the adhesive contacts the
undersides of the adjacent tiles, the adhesive prevents relative
movement between the adjacent tiles; and c. a sensor capable of
sensing one or more of pressure, moisture, pH, and temperature.
67. The method of claim 66, wherein the sensor is configured to
provide information to a radio frequency transponder.
68. The method of claim 66, wherein the sensor is configured to
transmit a wireless signal if the signal is above or below a
predetermined level.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/920,368 filed Mar. 27, 2007 and is a
continuation in part of U.S. patent application Ser. No. 11/018,947
filed Dec. 21, 2004 and is a continuation-in-part of U.S. patent
application Ser. No. 11/251,733 filed Oct. 17, 2005. U.S. patent
application Ser. No. 11/018,947 filed on Dec. 21, 2004 claims the
benefit of U.S. Provisional Application No. 60/619,340 filed Oct.
15, 2004 and is a continuation-in-part of U.S. patent application
Ser. No. 10/638,878 filed on Aug. 11, 2003, which claims the
benefit of U.S. Provisional Application No. 60/403,790 filed on
Aug. 15, 2002. U.S. patent application Ser. No. 11/251,733 filed on
Oct. 17, 2005 claims the benefit of U.S. Provisional Application
No. 60/619,340 filed Oct. 15, 2004 and claims the benefit of U.S.
Provisional Application No. 60/690,762 filed Jun. 15, 2005. The
contents of all are incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] Embodiments of this invention relate to systems and methods
for installing floor coverings, particularly including carpet tile
and other modular floor coverings.
BACKGROUND OF THE INVENTION
[0003] Floor coverings have been in use since before recorded human
history. The first such materials were undoubtedly animal skins or
plant materials like leaves or stems. Later, floor coverings were
manufactured, such as by weaving or knotting a variety of naturally
occurring fibers, including sisal and wool. Beginning in the
twentieth century, such fiber-faced floor coverings began to be
manufactured from man-made fibers as well.
[0004] While the first floor coverings were limited in size to the
size of an animal skin, later floor coverings expanded to cover
entire room floors. Such "wall-to-wall" installations of
"broadloom" floor covering came into wide-spread use in the
twentieth century. Paradigm installations of such materials utilize
one or a small number of pieces of broadloom carpeting to cover
entire room floors. This type of wall-to-wall floor covering is
generally attached to the floor in some manner.
[0005] Later, modular floor coverings utilized smaller, uniform
size modules or tiles in both solid surface floor coverings such as
vinyl tiles and in textile-faced floor coverings, usually called
carpet tiles. As explained in U.S. Patent Application Publication
2004/0258870 for "Re-Configurable Modular Floor Covering," filed
Aug. 11, 2003 (incorporated by reference), tiles may be installed
as area rugs that do not cover the entire flooring surface.
However, the vast majority of tiles are used in wall-to-wall
installations. Tiles have traditionally been installed in aligned
rows and columns, with the edges of each tile aligned with the
edges of adjacent tiles ("conventional carpet tile installation
method"). Conventional carpet tile has historically been a product
that sought to mimic the appearance of broadloom carpet and to hide
or at least de-emphasize the fact that the product was modular.
Achieving this result has required, at minimum, that carpet tiles
or modules be placed in a flooring installation with the same
orientation that the modules had at the time they were produced
(i.e., monolithically). However, textile face modular flooring
designers have recently begun to design flooring and flooring
installations that do not seek to mask, but rather celebrate, the
modularity of the flooring. For instance, while still installed in
aligned rows and columns, modules are installed "quarter-turned"
with each tile position rotated 90.degree. relative to each
adjacent tile. Moreover, carpet tiles have been developed that can
be installed "randomly" without regard to position or rotational
orientation as described in U.S. Pat. No. 6,908,656, which is
incorporated herein by reference.
[0006] Modules are not always installed in aligned rows and
columns, however. For example, tiles are also installed in aligned
columns that do not form aligned rows of modules so that a column
of tiles appears shifted up or down relative to adjacent tile
columns ("ashlar installation method"). In other installations,
tiles are installed in aligned rows that do not form aligned, but
rather staggered, columns ("brick-laid installation method").
[0007] While the floor covering modules are generally of relatively
substantial size and weight, which facilitates maintenance of the
modules in the positions they are placed when the floor covering is
assembled, it is desirable to provide a means for further resisting
module movement. This has traditionally been accomplished by
attaching the modules to the underlying flooring surface in a
variety of ways.
[0008] Modules are often glued to the floor by first applying a
layer of adhesive to the underlying flooring surface and then
positioning the tiles on top of the adhesive. With this method,
adhesive typically contacts the entire surface area of the
underside of the flooring modules, which increases material costs
and often leads to difficultly in re-positioning the tiles if they
are positioned incorrectly. This is a particular problem during
installation of patterned modules that must be matched at the
seams. Moreover, when the tiles are eventually removed, glue
remains on the flooring surface and that glue sometimes retains
portions of the removed tiles. The glue (and any flooring materials
held by the glue) must be removed from the floor to create a smooth
surface before installing new tiles. This adds both cost and time
to the installation process.
[0009] Modules may also be installed by pre-applying adhesive to
the entire underside (or any part) of the module. For example,
adhesive may be applied in a relatively narrow strip across each
module underside and covered, prior to module installation, by a
plastic film or paper strip that is peeled off just before module
placement. Again, however, this method involves attaching the
modules directly to the floor and can result in the consequent
drawbacks discussed above.
[0010] Modules have also be installed using double-sided adhesive
tape, whereby one side of the tape is positioned on the back of the
module and the other side of the tape is positioned on the floor to
thereby secure the module to the floor. Double-sided tape has also
been positioned between and along the entirety of adjacent carpet
and carpet tile edges. However, as with adhesive, double sided tape
can be unforgiving with respect to tile re-positioning and can also
leave a residue on the floor upon removal of the tiles. Moreover,
the tape has a low tensile strength and is relatively inelastic and
consequently is apt to stretch and not regain its shape. This can
result in the gaps formed between adjacent tiles.
[0011] In addition to direct attachment to the floor, modules have
also been indirectly attached to the underlying flooring surface,
such as with mechanical fasteners or adhesive covered pads. For
example, hook and loop fasteners have been used whereby a sheet of
either the hook or the loop is secured to the floor and the other
of the hook or the loop is provided on the back of the modules. The
hook or loop on the modules then engages the hook or loop on the
floor to secure the modules to the floor. Pads covered with
adhesive have also been used. For example, a foam pad pre-coated on
both sides with a releasable adhesive has been used. During
installation, release paper is removed from both sides of the pad
to expose the adhesive, and the pad is attached to the floor.
Carpet tiles are then positioned on top of the pad and held in
place by the adhesive. While these systems and methods may improve
the installers' ability to re-position the tiles, they
significantly increase the material cost of the installation.
Moreover, with these installation methods, the tiles are more
likely to move relative to each other and thereby create gaps in
the installation.
[0012] Other installation methods exist whereby the tiles are
neither directly nor indirectly attached to the floor. For example,
one-sided adhesive tape, such as duct tape, has been used to secure
adjacent tiles together. The tiles are positioned face down and the
tape is secured along the entirety of the adjacent edges of the
tiles. The tiles must then be carefully turned over to expose their
wear surfaces without breaking the connection between adjacent
tiles. This method requires a significant amount of time to
position the tape on the tiles as well as a significant material
investment to tape adjacent tile edges together along the entirety
of the seams. Moreover, such adhesive tape is relatively flimsy,
making it challenging to position the tape as desired on the
underside of tiles, and, as with double-sided adhesive tape,
suffers from low tensile strength and inelasticity, rendering it
likely to permanently stretch when subjected to stress and thereby
create permanent gaps between adjacent tiles.
[0013] Regardless of the method of installation, tiles are often
inadvertently installed over surfaces that have a high moisture
content and a high pH. If the carpet tile is installed directly
over high-moisture content flooring, then an undesirable smell may
result due to moisture trapped between the floor surface and the
tile. Traditionally, to combat this problem, a sealant has been
applied to the floor surface before adhering the tile to the
floor.
[0014] Moreover, carpet tiles have been manufactured with a cushion
backing, which is desirable for comfort. Traditionally, the cushion
layer is attached directly to the carpet tile so that, if the
carpet tile is later removed or replaced, the cushion is
necessarily removed with the tile.
[0015] While methods for installing floorcoverings exist, a need
exists for a system and method that reduces both the time and
material costs needed to install modules into a stable
floorcovering.
SUMMARY OF THE INVENTION
[0016] Embodiments of this invention addresses the problems of
previous modular flooring installation methods by providing systems
and methods that reduce the time and material costs required to
install a floor covering. Connectors are used to join adjacent
floor covering units. The connectors are particularly useful in
installing modular floor covering units ("tiles"). In one
embodiment, the connectors include a film and an adhesive layer
coated on one side of the film. To install tiles using the
connectors, a first tile is placed on the floor at a position
determined by conventional tile installation methods. A connector
is positioned so that the adhesive layer faces upward and does not
contact the floor. The connector is typically positioned so that
only a portion of the adhesive layer adheres to the underside of
the tile, leaving the remainder of the connector extending from the
underside of the tile. Tiles are then positioned adjacent the first
tile so that a portion of the connector adheres to the adjacent
tiles. In this way, the connectors span the adjacent edges of the
adjacent tiles. The tiles are assembled on a underlying floor
surface without the need to attach them to the floor surface.
Rather, the tiles are linked to each other with the connectors, so
that the tiles create a floor covering that "floats" on the
underlying floor surface.
[0017] The connectors need not be positioned along the entirety of
the adjacent edges nor even across all adjacent tiles edges in the
installation. Rather, the connectors are sized so that, when
positioned in the installation, they do not extend along the entire
length of the adjacent edges. Moreover, while any number of
connectors may be used at any number of locations between adjacent
tiles, the benefits of this invention may be fully realized by
placing the connectors in strategic locations within the assembly
(such as at some of the corners where four tiles meet). This is in
contrast to prior installation methods that required stabilizing
material be placed along the entirety of adjacent tiles edges so
that all adjacent tiles edges in the installation were
stabilized.
[0018] The size and relatively minimal number of connectors needed
to stabilize a tile installation can result in a significant
reduction in material costs from prior tile installation methods.
Moreover, use of the connectors significantly reduces tile
installation time by obviating the need to prep a floor prior to
installation. Instead of the installer applying a layer of adhesive
to the floor and then retracing his steps to position the tiles on
the adhesive layer, with the connectors, the installer positions
and secures as he goes. Moreover, given the releasable adhesive
used on the connectors and the limited surface area of the tiles
that contacts the connectors, the tiles can easily be re-positioned
if necessary. Furthermore, because the tiles do not interact with
the underlying floor, they are easily removable from the floor and
leave the underlying floor with little or no residual adhesive upon
such removal. Consequently, the floor does not require refinishing
before it is recovered with another floorcovering.
[0019] Additionally, the connectors can be adapted to conduct
electricity. When the conductive connectors are secured to the
tiles, electrical continuity is maintained through adjacent tiles.
This makes it possible to conduct electricity through the tiles for
use with security systems, voice and data transmission,
electromechanical membranes, tracking and location monitoring,
wayfinding (e.g., when a person walks on the floor, the floor is
illuminated in some manner by which to assist the person to find
his/her way), and many other alternatives.
[0020] Installation can be expedited through use of a dispenser
that holds connectors and that preferably also produces individual
connectors in a ready-to-grasp fashion. The dispenser may have a
mechanism for separating the connectors from a release layer or
from other connectors. The dispenser may be secured to an
installer's belt and leg and may include connectors in a roll,
connectors on a roll of release material, connectors on fan-folded
release material, or individual connectors, as examples. The
dispenser may be refillable or designed for single use.
[0021] Preferably the dispenser has a housing for release material
in a strip bearing connectors at successive intervals along the
length of the strip. The dispenser also has an opening for
presenting connectors to the user and may also have an actuator for
controlling the release and presentation of a connector through the
opening to the user. The dispenser also may have one or more
attachment members such as a belt loop or leg strap for securing
the dispenser to the user. During carpet installation, the
dispenser is secured to the carpet installer using an attachment
member so that the installer may move around the room to install
carpet tiles using the dispensed connectors. To acquire a
connector, the carpet tile installer moves the actuator to cause a
connector to be released from the release material and presented
through the opening where it may be easily grasped. The connector
may then be attached to one or more carpet tiles. Another
embodiment provides a dispenser with a housing having an opening
for connectors to exit and an actuator actuated by hand movement
from a first position to a second position that is closer to a
desired location on the floor surface and closer to the opening
than the first position. The dispenser opening may be within hands
reach of the second position of the actuator, so that a first
portion of a user's hand can contact the opening and the same time
a second portion of the user's hand contacts the actuator in its
second position. This allows a user to easily grasp a connector
presented from the opening after moving the actuator from the first
position to the second position.
[0022] In another embodiment of the invention, a stack of
connectors each having adhesive on one side are bonded or otherwise
attached together. The individual connectors in the stack of
connectors may be bonded or attached together in a variety of ways.
For example, the adhesive on the adhesive side of one connector may
be releaseably attached to an adjacent connector's opposite side
that may be coated with a release coating to prevent the adhesive
from forming a permanent or hard-to-detach bond. Generally, the
adjacent connectors in a stack are oriented in a similar direction
and aligned. As another example, a release layer may separate the
adjacent connectors, with the adhesive layer of a first connector
attached to a release material and the opposite side of a second
connector also attached to the release material. As yet another
example, the stack of connectors may be successive connectors
attached on a single strip of release material folded such that
adjacent connectors on the strip overlap one another in the stack,
i.e. fan folded release material. A stack of connectors may also be
included within a dispenser that assists a user in removing an
individual connector from the stack of connectors. During carpet
installation, a carpet installer may use a stack of connectors by
removing an individual connector from the stack and attaching it to
the underside of the carpet edge.
[0023] Another embodiment of the invention provides a connector
having a film with a layer of water-based or synthetic
polymer-based adhesive on one side. The adhesive may have low or no
volatile organic content and may be plasticizer resistant.
[0024] Another embodiment of the invention provides for an
intermediate substrate between the connected tiles and the
underlying flooring surface. For example, a film and/or cushion may
be positioned on the floor prior to tile installation. The film
and/or cushion is preferably moisture resistant and serves as a
barrier to prevent moisture present in the existing floor from
contacting the tiles. The film and/or cushion thus eliminates the
need for traditional sealants and barrier coatings. The cushion
additionally provides comfort underfoot and eliminates the need to
use cushion back carpet tiles. Rather, hard back carpet tiles may
be installed over the cushion to impart the desirable cushioning
characteristics. If the tile becomes soiled or worn, it can be
removed without removing the cushion. In this way, the cushion can
remain on the floor and be reused.
[0025] Yet another embodiment of an intermediate substrate provides
a cushion composite suitable for carpet-on-carpet installation,
where new carpet tiles are placed on top of existing carpet tiles
or wall-to-wall carpeting. The new tiles can be installed using the
connectors described above. This embodiment provides for the
temporary or permanent replacement of carpeting at reduced cost, as
the current tiles or carpet need not be removed prior to
installation of the new carpet tiles. Additionally, the new tiles
can be removed without damage to the existing tiles or wall-to-wall
carpeting.
[0026] Regardless of the type of intermediate substrate used (if
any), in one embodiment all of tiles placed atop the intermediate
substrate are connected together using the connectors disclosed
herein. In this way, none of the layers in the installation are
connected to any other layer in the installation (e.g., the
intermediate substrate is not connected to the floor and the
carpeting or tiles are not connected of the intermediate
substrate). In this way, the flooring may be easily removed without
requiring clean-up and preparation before installation a subsequent
floorcovering.
[0027] The connector may have alignment indicia for facilitating
installation of carpet tiles. Such indicia include markings,
colors, and objects such as crosshairs, lines, dots, blocks, and
multi-color segments and quadrants.
[0028] Another embodiment of the invention provides a method of
installing carpet tile using connectors with adhesive on one side.
An installer places a carpet tile in or near its desired
installation position on a floor surface with the underside of the
tile resting on the floor surface. The installer uses one hand to
lift an edge, corner, or other portion of the tile and the other
hand to attach a connector adhesive side up to the edge or other
part of the underside of the portion of the tile such that an
exposed portion of the connector extends beyond the edge of the
tile. The installer then places a second tile adjacent the first
and attaches the underside of the second tile to the exposed
portion of the connector. A dispenser may provide the connector to
the installer with the adhesive side up and in a location
convenient to the portion of the carpet tile to which the connector
is to be attached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is perspective view of one embodiment of a connector
and release layer of this invention.
[0030] FIG. 1A is perspective view of one embodiment of a
conductive connector.
[0031] FIG. 2 is a perspective view of another embodiment of
connectors and a release layer of this invention.
[0032] FIG. 3 is a top plan view of yet another embodiment of
connectors of this invention.
[0033] FIG. 4 is a schematic view of one embodiment of a connector
dispenser of this invention.
[0034] FIG. 5 is a bottom plan view of an installation of tiles
pursuant to this invention.
[0035] FIG. 6 is a bottom plan view of a subset of the tiles of
FIG. 5.
[0036] FIG. 7 is a bottom plan view of another installation of
tiles pursuant to this invention.
[0037] FIG. 8 is a bottom plan view of a subset of the tiles of
FIG. 7.
[0038] FIG. 9 is a side schematic view of an embodiment of a
connector of this invention attached to a tile edge.
[0039] FIG. 10 is a perspective view of a connector dispenser.
[0040] FIG. 11 is an exploded perspective view of the connector
dispenser of FIG. 10.
[0041] FIG. 12 is a side view of the connector dispenser of FIG.
10.
[0042] FIG. 13 is a side view of the connector dispenser of FIG. 10
with the front cover of the housing removed.
[0043] FIG. 14 is a side view of the drive pack of the connector
dispenser of FIG. 10.
[0044] FIG. 15 is a front view of the drive pack of the connector
dispenser of FIG. 10.
[0045] FIG. 16 is a cross-sectional view of an embodiment of a film
positioned between a carpet tile and a flooring surface.
[0046] FIG. 17 is a cross-sectional view of an embodiment of a film
and a cushion positioned between a carpet tile and a flooring
surface.
[0047] FIG. 18 is a cross-sectional view of an embodiment of a
cushion positioned between a carpet tile and a flooring
surface.
[0048] FIG. 19 is a cross-sectional view of an embodiment of a
cushion composite of this invention.
[0049] FIG. 20 is a cross-sectional view of the cushion composite
of FIG. 19 positioned between existing carpet or tile and a new
carpet or tile.
[0050] FIG. 21 is a top plan view of a radio frequency transponder
embodiment of a connector.
DETAILED DESCRIPTION OF THE DRAWINGS
[0051] Embodiments of this invention relate to systems and methods
for installing floor covering. One of skill in the art will
understand that the systems and methods described herein may be
used in a variety of floor covering installations. However,
applicants have found the connectors described herein particularly
useful in any type installation (including wall-to-wall and area
rug installations) of modular floor covering units (hereinafter
referred to as "tiles"). The tiles may be of various colors and
textures in a range of sizes and shapes. For example, individual
tiles may be in a shape that simulates wood planking or shapes of
ceramic and other tiles, including, but not limited to, hexagons,
squares, rectangles, triangles and other shapes. In addition, the
tiles may be provided in a variety of textures. Tiles of this
invention may typically be conventional carpet tile with textile
faces (including, but not limited to, tufted, bonded, and printed
faces), but could also be other modular materials, including woven
and nonwoven textile flooring, solid vinyl, ceramics, leather, or
any other suitable material. The tiles are preferably installed on
a generally smooth surface, including, but not limited to plywood,
laminates, linoleum, vinyl tile, hardwoods, and concrete. However,
as discussed below, the tiles may be installed on an intermediate
substrate, including pad and broad loom carpet, located between the
tiles and the underlying floor.
[0052] FIG. 1 illustrates one embodiment of a connector 20 of this
invention. The connector 20 includes a film 22 and an adhesive
layer 24 coated on one side of the film 22. A release layer 26 is
placed on top of the adhesive layer 24 to protect the underlying
adhesive. In use, the release layer 26 is removed from the
connector 20 to expose the adhesive layer 24. As will be described
in more detail below, the connector 20 is then positioned so that
the adhesive layer 24 contacts the underside of adjacent tiles to
span the adjacent edges of the tiles and thereby connect the tiles
together to form a floor covering. In this way, the tiles are
assembled on a underlying flooring surface without the need to
attach them to the floor surface, so that the tiles create a floor
covering that "floats" on the underlying floor surface.
[0053] The film 22 may be of any suitable material, but, to
facilitate rapid flooring installations in accordance with this
invention, is preferably made of a material that is relatively
stiff so that a connector positioned partly in contact with the
underside of a tile will project beyond the edge of the tile in
roughly the same plane as the underside of the tile. This
facilitates proper positioning of the projecting connector portion
to make appropriate contact with an adjacent tile. This is
typically greater stiffness than most adhesive tapes that will
significantly curl or droop down from an underside of a tile to
which a portion (but not all) of a length of such adhesive tape is
attached. At the same time, the film 22 from which connectors of
this invention are made should be sufficiently flexible to
facilitate handling the connectors in a roll if desired and to
permit the connectors to conform to floor or tile
irregularities.
[0054] The film 22 should also resist shrinkage, which can result
in buckling of adjacent tiles, and exhibit a relatively high
tensile strength to resist stretching under foot traffic and
rolling loads. For example, materials that exhibit a tensile
strength between 160-270 mega Pascals ("MPa") in the machine
direction and 165-210 MPa in the cross-machine direction have been
found particularly suitable for this application. Moreover, the
percentage by which the material may be elongated or stretched
before breaking should also be relatively high to prevent connector
breakage and failure when subjected to tensile stresses. For
example, it is preferable, but not required, that the material used
be capable of being stretched 120-200% of its machine direction
dimension and 150-170% of its cross-machine direction dimension
before breaking.
[0055] Polymeric materials, paperboard and other materials
including textiles and metals that are suitably stiff, thin,
strong, water-resistant and inexpensive may also be used for film
22. However, the film 22 is preferably a synthetic polymer
material, such as a polyolefin, a polyamide, or a polyester, and
more preferably polyethylene terephthalate ("PET") polyester. These
materials are relatively cheap, will conform to the underlying
floor in use, and will resist corrosion. While not necessary, it is
preferable that the film material be recyclable.
[0056] The film 22 preferably has a thickness between 0.0005 and
0.015 inches, inclusive, and more preferably between 0.003 and 0.01
inches, inclusive, and even more preferably is 0.005 inches. The
film 22 may also have, but does not have to have, a primer coat
(not shown in the figures), such as a coating of acrylic, applied
to the same side on which the adhesive layer 24 is to be applied to
promote adhesion between the film 22 and the adhesive layer 24. The
film 22 may be corona treated on one or both sides to increase
surface tension and promote adhesion between the film 22 and the
adhesive 24 without the use of adhesion promoting coatings.
[0057] The film 22 may be any shape, including, but not limited to,
a circular shape or any rectilinear shape such as a square or
triangular. A square shape is suitable for most installations.
Moreover, the size of the film 22 can depend on the size of the
tiles being installed. However, as a general rule, the surface area
of the film 22 can be as little as 1%, and preferably between 2-5%,
of the surface area of the tiles for which the connectors are
intended to be installed. It has been found that a connector
surface area over nine square inches does not meaningfully
contribute to the stability of an installation of 18 inch square or
50 centimeter square tiles. Thus, connectors 20 desirably should
be, but do not have to be, no larger than about three inches by
three inches square to conserve materials and limit expense.
[0058] While the adhesive layer 24 can be any adhesive that
exhibits certain attributes desirable for use in this invention,
the specific type or amount of adhesive used in the connector may
often depend on the tile with which the connector 20 is intended
for use. Some carpet tiles have backings containing plasticizer to
increase flexibility and/or change other characteristics of the
backing. Plasticizer has a tendency to migrate and may migrate into
certain connector adhesives. This migration may weaken the adhesive
properties of the connectors making them less effective.
Water-based adhesives (rather than solvent based adhesives) with
little or no volatile organic content ("VOC") may be plasticizer
resistant and are thus generally preferable in cases where
plasticizer migration resistance is desirable (i.e., in
installations of carpet tiles containing plasticizer). Acrylic
adhesives, including those sold by 3M under the identification
numbers 9465, 6032, 6035, and 6038, and in particular 9465 (which
is primarily an acrylate terpolymer) and 6032 (a tackified acrylate
copolymer), are suitable. Moreover, the adhesive 24 preferably, but
not necessarily, is resistant to water and typical carpet cleaning
detergents. It is also preferable to use a releasable adhesive.
[0059] The adhesive layer 24 in all connectors 20 should adhere
well to the back of the tiles. However, the adhesion to the tile
should not be so strong as to prevent removal and repositioning of
the tile relative to the connector 20, if necessary. If the bond
strength between the tile and the adhesive (i.e., the amount of
force required to separate the adhesive layer 24 from the tile
backing, which can be measured using the ASTM D-3330 test (commonly
referred to as the "90 degree peel test")) is too strong, the
adhesive layer 24 will peel from the film and remain with the tile,
thereby destroying the connector. Thus, the bond strength between
the adhesive layer 24 and the tile should not be stronger than that
between the adhesive layer 24 and the film 24.
[0060] The bond strength is preferably between 5-100 ounces/inch,
inclusive, at room temperature. The preferable bond strength may
depend on the tile backing. For example, the bond strength between
the adhesive and hardback tiles, such as, for example, those made
from PVC, polyurethane, or polyolefin, is preferably about 50-70
ounces/inch. The bond strength between the adhesive and tiles
having a textile backing, such as for example a woven polypropylene
or felt backing, is preferably about 10-60 ounces/inch. Moreover,
the bond strength between the adhesive and cushion back tiles is
preferably about 40-60 ounces/inch, and the bond strength between
the adhesive and bitumen backed tiles is preferably about 10-20
ounces/inch. It is preferable that the bond strength between a tile
and the adhesive at elevated temperatures remain within +/-15% of
the bond strength at room temperature.
[0061] The amount of adhesive (i.e., the thickness of the adhesive
layer) provided on each connector 20 can depend both on the size of
the connector 20 as well as the tile to be used with the connector
20. However, it is preferable that, while the amount of adhesive
should enable the connector sufficiently to contact and engage the
underside of the tile to achieve the bonding strengths set forth
above, it should not be so much that the adhesive migrates beyond
the interface of the connector 20 and tile to contact the
underlying floor. In this way, the floorcovering installation will
remain unsecured to the underlying floor to facilitate the eventual
removal of the modular units. A connector 20 with an adhesive
thickness about 0.0005-0.010 inches, and more preferably about
0.002-0.008 inches, has been found suitable for most
applications.
[0062] For tiles having a woven or knitted textile backing, more
adhesive will typically be necessary to penetrate the cavities
formed in the backing and thereby provide sufficient interfacial
contact between the tile and adhesive. Connectors having an
adhesive layer 24 that is about 0.005-0.008 inches thick is
preferable for tiles having textile backings. For tiles having a
relatively flat or shallow embossed backing surface, such as hard
back tiles, less adhesive, preferably with a thickness in the range
of 0.002-0.003 inches, may be used.
[0063] All of the adhesives contemplated for use on the connectors
should also have sufficient sheer strength to prevent the tiles
from moving relative to the connectors or each other and thereby
creating gaps between adjacent tiles after installation.
[0064] Although not shown in the figures, it is possible to provide
a logo or other design elements on the connectors 20. For example,
a logo may be inked on the side of the film on which the adhesive
is to be applied. In this way, the ink, which typically has a high
VOC content, is trapped between the film and the adhesive,
preventing any undesirable emissions from the ink. Moreover, when
the connector is positioned on the release paper, the logo is also
protected by the film. This prevents the logo from being
accidentally scratched off or otherwise removed from the
connector.
[0065] It may be useful to print or otherwise provide on the
connectors alignment indicia (not shown in the figures) for
facilitating installation of the tiles. The installer then need
only align the tile edges (or other portions of the tiles) with the
indicia to ensure that the connectors are optimally placed between
adjacent tiles. Any indicia that would convey to the installer
where the tiles should be placed on the connectors can be used. For
example, connectors can be provided with crosshairs, divisional
lines parallel and transverse to the edges of the connectors, dots,
blocks, etc. Moreover, different portions of the connectors can be
colored (such as by dividing the connectors into quadrants and
imparting a different color to each quadrant) to indicate proper
carpet tile positioning.
[0066] Chemical sensors may be placed on the connectors 20 to
monitor the moisture content of the underlying floor. If the
moisture content rises above a pre-determined level, the sensor
transmits a wireless signal. In this way, the moisture content of
the floor can be monitored and remedial measures specifically
directed to the problem areas taken.
[0067] Moreover, pressure sensors may also be associated with the
connectors 20. For example, if someone falls on the floor, the
pressure sensor would alert a control system (such as via wireless
signaling) that the pressure on a given area of the floor has
exceeded the pre-determined level. The sensor thereby acts as a
guide to the precise location of elevated pressure. Such technology
could be particularly useful in homes for the aged or hospitals,
where caregivers need constant assurance that their charges are
safe (i.e., have not fallen and cannot get up).
[0068] In yet another embodiment, the connectors can be equipped as
radio frequency identification ("RFID") tags by including radio
frequency transponders. A radio frequency transponder is any kind
of radio transmitter and/or receiver that is activated when it
receives a radio frequency signal. The transponders can be
incorporated within or otherwise attached to a connecter in any
manner. One or more transponders may be imprinted on one or more
connectors used in an installation, as examples, a transponder
could be imprinted on either side of the film or on an inlay that
is attached to the film of a connector. It is not necessary,
however, to have a transponder on every connector in an
installation. Various configurations may be used including those
depicted in the Figures.
[0069] FIG. 21 is a top plan view of a radio frequency transponder
embodiment of a connector 320. The connector 320 may comprise a
film with an adhesive layer that incorporates or otherwise attaches
to a sheet 322 that contains or otherwise has one or more radio
frequency transponders. Alternatively, the components of a
transponder may be directly incorporated or otherwise attached on
the connector film. In certain embodiments, a radio frequency
transponder is attached to the connector film, meaning that the
radio frequency transponder is directly or indirectly (e.g., as
part of a sheet 322 or through any other intermediates) connected
to or positioned adjacent to the connector film. The sheet 322 may
further comprise a layer of adhesive or a face (paper or polymer)
with a layer of adhesive. The radio frequency transponder comprises
a coupling element 324 that is bonded to or otherwise used with an
integrated circuit chip 328. The coupling element 324 may comprise
a conductive material like copper or aluminum shaped as a coil or
that otherwise acts as an antenna. The radio frequency transponder
may also comprise a bridge 326 that connects the ends of the
coupling element 324 to complete a loop and form a circuit. The
integrated circuit chip 328 is an electronic microchip that may be
readable and/or writable.
[0070] While FIG. 21 depicts a High Frequency ("HF") transponder
incorporated in a connector 220, an ultra high frequency ("UHF")
transponder or any other type of transponder could be used instead,
for example, the connector 220 could comprise a transponder that
has a single layer of conducting material or that extends from
opposite sides of an integrated circuit chip to form shapes that
are mirror images of each other. Radio transponder components may
be inlayed, printed, or incorporated as part of a connector in any
other manner. Radio transponder components may be passive, MEM
passive, semi-active, active, or employ any other information
technique. The components may or may not include batteries and/or
software to control efficiency. One or more of the radio frequency
transponder components may comprise metal, organic polymers, or any
other material. Radio transponder components may include, but are
not limited to, RFID components manufactured by Alien Technology
Corporation, Avery Dennison Corporation, Texas Instruments
Incorporated, Omron Corporation, and UPM Raflatac, among
others.
[0071] Alignment indicia 330 (including, but not limited to,
crosshairs, lines, dots, blocks, and multi-color segments and
quadrants) may be provided on the connector 320 to provide guidance
for an installer wishing to position the connector 320 at a corner
or edge of a carpet tile. A connecter may be positioned at a
corner, at an edge, or simply on the back of a tile. In a
multi-tile installation, some connectors may span the edges of
adjacent tiles and others may simply be placed on the tile backs,
i.e., each attaching to a single tile.
[0072] Connectors comprising radio frequency transponders offer
RFID capability and may be positioned in any arrangement while
installing a flooring surface. The connectors may be positioned to
create an intelligent floor covering that has embedded components
regularly spaced from one another. For example, the connectors may
be regularly spaced, juxtaposed tile corners of the tiles, as shown
in FIGS. 5, 6, 7, and 8. One benefit of certain embodiments is the
creation of an array of regularly spaced radio frequency
transponders that can send, store and/or receive information
without requiring any additional installation beyond what is
already required to use the connectors to secure the tiles. Such an
array may be used to create a x-y grid or other map of the
regularly arrayed components. For example, a robotic device may be
moved over the grid to identify the relative positions of the tags
to one another. These relative positions may used to map out the
positions of the transponders in the array. A map may also be
created if connectors are positioned irregularly. A map may be
generated, for example, using a simulation localization and mapping
("SLAM") technique. In any case, such a map may be used with or
incorporate a floor plan and/or a mapping program so that the radio
transponder mapping can be used to identify the physical location
of one or more radio transponder readers. As a radio transponder
reader moves around, it can record the sequence of radio
transponders it reads and send (for example, via wireless
transmission) this information to a tracking station that monitors
the real-time location of the equipment or person carrying the
reader. In a multi connector installation, the radio frequency
transponders of the different connectors may operate on the same or
different frequency. For example, in one embodiment, the
transponders in an installation range from low to high frequency.
Information may be sent on different channels, each associated with
a particular radio frequency transponder component. A radio
frequency reader may further comprise a writer that sends
information that is recorded on one or more of the radio frequency
transponders. For example, it could send information identifying
that vacuuming has occurred or the date that vacuuming has
occurred. As another example, it could send position information
relating to the relative or map position of the transponder
receiving the information, e.g., x,y or x,y,z coordinates. This
information could be provided when the transponder is read by other
reading devices.
[0073] Generally, connectors equipped with radio transponders can
facilitate a number of broad functions, including tracking,
verification, tracing, positioning, and authenticating. By way only
of example, connectors equipped with RFID technology can be used to
locate the position of people, items, or equipment, for example
tracking the location of a firefighter or firefighting equipment.
They could also be used to track traffic patterns of people or
equipment or to guide equipment to precise locations to perform
specific functions.
[0074] In one application, the radio frequency transponders serve a
mapping function to guide equipment equipped with a radio frequency
component reader. For example, a reader can be placed on a vacuum
cleaner or other cleaning machine. The reader may be programmed
with a sequence of unique transponder numbers that are on the
connectors in a room. When a robotic vacuum is so programmed and
activated, the radio frequency transponders on the connectors in
the room may be read by the robotic vacuum's reader and used to
guide the vacuum towards the connectors in the order that the
connectors' transponder numbers appear in a programmed sequence. In
this way, the entire floor can be automatically cleaned or
otherwise maintained. The transponder numbers of connectors
positioned in higher traffic areas can appear more often in the
sequence to ensure that those areas are cleaned more thoroughly. A
variety of radio transponder readers may be used including readers
offered by APSX, LLC.RTM. and Skyetek, Inc..RTM.
[0075] In another embodiment, other types of robots are equipped
with a reader. The reader can be programmed with a sequence of
transponder numbers so as to lead the robot to various locations.
For example, the reader on a robot in a hospital can be programmed
to guide the robot along a designated path so that the robot can
deliver medicines to rooms and perform other tasks. In addition to
radio frequency transponder equipped connectors providing a map
that a robot can follow to reach a desired location, the connectors
can help to precisely position the robot (or other non-manually
driven equipment). For example, if a robot needed to recharge at a
power supply, a connector with a transponder could be positioned
directly adjacent the power supply. In this way, the connector
would guide the robot to and properly position the robot relative
to the power supply for recharging.
[0076] In another embodiment, a shopping cart may be equipped with
a reader. The shopper may indicate the products desired, and the
radio frequency transponders on the connectors lead the cart to the
desired locations in the store. Reading devices can be used in a
variety of other contexts, including but not limited to in shopping
malls, museums, hospitals, entertainment venues, and in conjunction
with or otherwise facilitating global positioning systems.
[0077] Transponders can also be used to monitor the location and/or
movement of equipment. In one embodiment, hospital equipment is
equipped with a reader. The location of each piece of equipment in
the hospital can be determined when its reader reads a connector
transponder number, which is different from the other connector
transponder numbers. In another embodiment, movement of equipment,
such as a vacuum, can be monitored to determine whether an area has
been cleaned or not. For example, the reader on a vacuum (either
manually or robotically driven) can either store (to be downloaded
at a later time) or transmit (via wireless communication) to a
control system the connector transponder numbers that it reads in a
room. If a transponder number on a connector in the room is not
read, then the vacuum obviously did not clean in the vicinity of
the connector. In this way, information about the cleaning history
of a room can be recorded.
[0078] In a similar manner, the transponders on the connectors and
transponder readers on shopping carts and/or baskets can be used to
gather information about traffic flow in a store. In this way,
information about where people go in the store, how long they stay
in certain areas, etc. is gathered and can be used for a variety of
purposes, including designing the store lay-out to better
accommodate traffic flows and customer demand. Similarly, a reader
equipped shopping cart could include a display that presents
advertisements and other information to the shoppers based on the
areas where they are, where they have gone, and/or the areas they
have lingered.
[0079] A radio frequency transponder equipped flooring surface
provides a variety of potential benefits. In addition to
facilitating maintenance monitoring, equipment and person locating,
and robotic navigation, among the other things described herein, it
may be used to provide additional safety and security benefits in a
home, workplace, or other facility.
[0080] A radio frequency transponder and/or other RFID components
may be imprinted directly on or as part of a modular tile, for
example RFID components made of metal, polymer, organic polymer, or
any other material could be directly printed on the back surface of
modular tiles or any other component material. In one embodiment,
radio frequency transponders are imprinted on one or more of the
modular tiles near an edge or corner of each tile. When the tiles
are installed, connectors may be positioned to adhere to the
modular tiles in locations that covers or otherwise protect the
radio frequency transponders.
[0081] A floorcovering installation may also be equipped with both
sensors, such as chemical or pressure sensors, and radio frequency
transponders. The sensors may record information to the radio
transponders and the information may be harvested by a radio
transponder reading device, for example as part of maintenance
program. For example, a sensor may detect moisture content
information and record that information at a nearby radio
transponder. A connector can comprise one or more sensors and/or
one or more radio transponder components.
[0082] FIG. 1A illustrates an embodiment of a connector having
conductive properties (hereinafter referred to as a "conductive
connector"). The entirety of this disclosure should be understood
to apply to conductive connectors 150 as well as connectors 20.
[0083] As with the connector 20 described above, the conductive
connector 150 includes a film 156 and an adhesive layer 154 on one
side of the film 156. The conductive connector 150 additionally
includes a conductive component 152 secured to the film 15. For
example, the conductive component 152 may be secured to the film 15
with adhesive. Alternatively, the conductive component 152 may be
secured to the film 15 using any converting process, including, but
not limited to, lamination, molding, ultrasonic welding, etc. In
this particular embodiment, the conductive component 152 is a
rectangular strip (e.g., 1 inch in width) of conductive material,
such as copper foil, that runs across the width of the conductive
connector 150. While this embodiment shows a rectangular conductive
component 152 of copper foil positioned in the center of a
conductive connector 150, one of skill in the art will understand
that the conductive component can be made from any conductive
material, can be of any shape and size, and can be positioned
anywhere on the connector as long as, when positioned to connect
adjacent tiles, electrical continuity can be maintained between
adjacent tiles. Moreover, the conductive component could be on the
adhesive side 154 of the film 156 as shown, or on the opposite side
(provided means for ensuring conductivity between the underside of
the tile and the conductive element are provided).
[0084] The conductive connectors 150 can be used to connect
adjacent tiles together, as described above. Most carpet tiles
contain conductive materials, such as inorganic fillers like
carbon, calcium oxide, calcium carbonate, barium sulfate, etc.
Thus, when a conductive connector 150 is used to secure adjacent
tiles together such that the conductive component 152 contacts both
tiles, an avenue is provided by which electricity can be
transmitted across adjacent carpet tiles to form a conductive
surface. The formation of a conductive surface allows for the
transmission of electricity across the floor. This electricity can
be harnessed for a variety of applications.
[0085] For example, in one embodiment, the conductive connector 150
can be an electromechanical film made of a piezoelectric material
that produces an electric charge when pressure is exerted on it
(i.e., when someone is walking on the tiles). A device can then
receive and process the emitted signal and provide an alert to
those monitoring the device that a person is walking on the tiles.
This type of device has significance for security purposes and can
enable, for example, the monitoring of access to a restricted room.
Based on the signal that is produced when a person steps on the
carpet tile, it is possible to identify who is walking on the
carpet based on the person's gate. The system can then determine
whether the person has access to the restricted area or if the
person is an intruder. Moreover, because walking on the carpet
tiles generates electricity, it is contemplated that such
electricity can be harnessed and used to meet a building's energy
needs. It is conceivable that a building could eventually become
self-sustaining in terms of its energy needs using this
technology.
[0086] In another embodiment, the conductive connector 150 allows
transmission of electricity across the floor for voice and data
communication. When the entire floor surface is linked together in
a conductive fashion, the conductive connectors can serve as an
antenna for transmitting or receiving information. Alternatively,
the conductive connectors can function as a shield to prevent stray
wireless signals from entering or leaving an area.
[0087] Returning to FIG. 1, the release layer 26 may be any
material compatible with the adhesive such that the release layer
26 does not adhere to the adhesive to prevent its removal from the
connector. Kraft paper having a low energy coating, such as a
polymer coating (e.g., polymeric silicone), on at least one side
has been found to be particularly suitable in this application.
However, release materials suitable for use in this invention are
widely commercially available, such as from 3M, and readily known
to one of ordinary skill in the art.
[0088] The connectors 20 are preferably provided to the
installation site as individual units already entirely or partially
cut into the desired shape and size to be used in the installation.
While each connector 20 may be manufactured separately, economies
of manufacture may be achieved by first manufacturing a sandwich of
film 22, adhesive layer 24, release layer 26 larger than the
intended connector size, and then cutting the connectors 20 from
that sandwich. The adhesive layer 24 can be coated onto the desired
film 22, after which the release layer 26 is positioned in contact
with the adhesive layer 24 to form the sandwich. In another
manufacturing embodiment, the adhesive layer 24 is first applied to
the release layer 26, after which the film 22 is positioned onto
the release layer 26 to form the sandwich.
[0089] The resulting sandwich may obviously then be cut into
connectors 20 of the desired shape and size. However, a number of
connectors 20 is preferably provided on a single release layer 26.
For example, multiple pre-cut or perforated connectors 20 may be
positioned consecutively along a strip of release layer 26. For
ease of handling and storage, this strip can be rolled so that the
connectors are positioned on the outside (see FIG. 2) or inside of
the roll or folded between consecutive connectors 20 into an
accordion shape. Moreover, a number of connectors 20 may be
provided on a sheet of release layer 26. The film 22 may be
provided with perforations 28 (see FIG. 3) or may be fully cut into
the desired connector shape and size for ease of removal from the
release layer 26 (not shown) during installation. The ideal number
of connectors 20 provided on a strip or sheet of release material
will obviously vary depending on the size of the installation.
[0090] Provision of the connectors 20 on a strip or sheet of
release material has been found to facilitate removal of the
connectors 20 from the release layer 26 and thus reduce
installation time. With respect to connectors 20 provided on a
strip of release material (as shown in FIG. 2), installation can
also be expedited through use of a connector dispenser that holds
at least one rolled or accordion folded strip of connectors 20 and
that preferably also provides a mechanism for separating the
connectors 20 from the release layer 26. The dispenser, which, for
example, may be fashioned as a backpack or mounted on the
installer's belt, preferably includes structure for supporting at
least one roll of connectors 20 (and preferably more).
[0091] In one embodiment of such a dispenser (see FIG. 4), a roll
of release material bearing connectors 20 is housed in a box 30
made from any sufficiently-rigid material, such as, for example,
plastic, metal, or cardboard. The box preferably includes three
openings 32, 34, 36 through which the strip of release material is
fed. The strip of release material is fed through the first opening
32, at which opening is positioned a projection 38. The release
material is then fed back into the box 30 through a second opening
34 and out a third opening 36. In use, the installer pulls on the
release material strip extending from the third opening 36. This,
in turn, advances from the roll portions of the release layer 26
bearing connectors 20. As the release layer 26 extends over the
projection 38, the connector 20, which is relatively rigid, is
unable to conform to the shape of and travel over the projection
38. Instead, the connector's leading edge disengages from the
release layer 26, after which the installer can easily grip the
disengaged edge to remove the connector 20 fully from the release
layer 26. Obviously, the more connectors the dispenser is able to
support, the fewer times the installer must re-load the dispenser
during installation. This can be especially beneficial during large
installations.
[0092] In another embodiment of such a dispenser (see FIGS. 10-13),
the dispenser 70 includes a housing 72 that holds connectors on a
roll of release material 74. An actuator 76 is moved from an upper
location or starting position down along the path of a slot 78 in
the housing to trigger the release of a single connector from the
roll of release material 74. The dispenser 70 separates a connector
from a release material and produces an individual connector in a
ready-to-grasp fashion such that the user's exposure to the
adhesive side of the connector is limited. Specifically, the
housing 72 has an opening 80 for presenting connectors in a
location near the final location of a user's hand after moving the
actuator 76 along slot 78 to trigger the release of the connector.
Thus, moving the actuator 76 from a starting position to a
finishing position along the linear path of slot 78 causes an
individual connector to be released (or partially released) from
the release material and presented through the opening 80 to the
user in a convenient location for the user's hand to grasp. Once
the user's hand releases the actuator 76, the actuator 76 returns
to its starting position at the top of the slot 78. The starting
position of the actuator 76 is preferably located in a convenient
location for the user, such that when the dispenser 70 is attached
to the user's anatomy the actuator 76 will be located convenient to
the user's hand, limiting the amount of movement necessary for a
user to grasp and move the actuator 76.
[0093] The dispenser 70 may be secured to the installer's belt with
belt loop 82 and to the installer's leg with a strap (not shown)
through openings 84 in a leg mount 86 attached to the housing 72.
The leg mount 86 has a curved shape and is formed of a relatively
flexible material (e.g., rubber) such that when a strap through
openings 84 is tightened around an installer's leg, the leg mount
86 forms a cushion conforming to the shape of the leg between the
leg and the housing 72. Alternatively, the leg mount 86 and housing
72 may be one piece. The dispenser may have a variety of attachment
members (e.g., belt loops, openings for straps, straps, clips,
etc.) for securing the dispenser to a user.
[0094] FIG. 11 is an exploded perspective view of the connector
dispenser 70. The drive pack 88 with rotating chain 90 is attached
to a drive member (shown in FIGS. 14-15) that drives take-up roller
96 and a drive member (also shown in FIGS. 14-15) that drives meter
roller 98. These rollers 96, 98 are also attached and rotate on
take-up rod 92 and meter roller rod 94, respectively. One or both
of these rods may use a ratcheted slip clutch to allow one to be
overdriven with respect to the other. When assembled and in use,
upon movement of the actuator 76 along slot 78, the rotating chain
90 of the drive pack 88 rotates and causes both take-up roller 96
and meter roller 98 to rotate. This causes the release layer 104 to
travel around pin 116, which in turn causes the relatively flexible
release material to bend around the curve of the pin 116 and the
relatively stiff connectors to release from the release material
and protrude through opening 80. Tensioning device or capstan
assembly 102 fits adjacent to meter roller 98 when assembled. The
tensioning device 102 is a pair of spring loaded rollers designed
to push against meter roller 98 and in use keeps the release
material 104 tightly up against meter roller 98.
[0095] The roll of release material 74 fits on spindle or peg 106
with the release material 104 extending to a tip portion 108. When
the dispenser is assembled, the roll of release material 74 is
loaded by inserting the roll 74 on peg 106 and feeding the release
material 104 on an appropriate pathway through the dispenser 70
ending with tip 108 attached to take-up roller 96. Tip 108 may
attach to take-up roller 96 by inserted tip 108 into slot 110 of
take-up roller 96, using an adhesive on tip 108 to adhere the tip
108 to the perimeter of take-up roller 96, or by any other suitable
technique.
[0096] When a roll 74 is properly inserted within a dispenser 70, a
first connector on the roll 74 may be ready to be presented. This
first connector may be spaced a predetermined distance from the tip
108, such that when the tip 108 is inserted in the slot 110 of
take-up roller 96, the first connector is in an appropriate
position. In other words, the first connector is positioned on the
release material following a leader and tip 110 portion of
predetermined length. Subsequent connectors are spaced along the
release material 104 throughout the remainder of the roll 74. In
most cases, the distance between connectors along the strip of
release material will be relatively constant amongst the
connectors.
[0097] After the actuator 74 causes the first connector to be
presented from opening 80, the release material 104 has advanced so
that the next connector is ready to be presented. Thus, the
dispenser 70 is self aligning because movement of the actuator 74
will usually advance the release material 104 slightly more than
the length of one connector putting the next connector to be
presented in proper position. Adjustment screw 112 allows a user to
fine tune or otherwise adjust the initial position of the actuator
thus lengthening or shortening the distance the actuator is moved.
This change is reflected in a change in the amount of release
material 104 movement along the path when the actuator is moved
from initial position to ending position.
[0098] FIG. 13 is side view of the connector dispenser 70 with the
cover removed that further illustrates the path of the release
material 104. As shown, the path of the release material 104 begins
at roll 74, extends along curved portion 114 to a sharp bend around
free rotating rod 116 located near opening 80, extends between
meter roller 98 and the tensioning device 102 up to the perimeter
of take-up roller 96. In use, movement of the actuator 76 causes
both the take-up roller 96 and the meter roller 98 to rotate
predetermined amounts. This rotation, in turn, causes the release
material 104 to advance a predetermined distance along the path
described above. Generally, the release material will advance a
sufficient distance to allow a connector on the release material
104 to detach or partially detach from the release material 104 and
protrude from opening 80 for the user to grasp and use.
[0099] FIG. 12 is a side view of the connector dispenser 74 with
the cover on. Generally, the dispenser housing will have two parts
that allow the housing to be opened for loading and unloading of
rolls of connectors on release material. The two parts may be
connected together by a hinge and open in clamshell fashion. A
latch 118 secures the two parts of the housing 72 together allowing
a user to quickly and easily reload the dispenser 70 when needed.
The positioning of the latch also allows a user to reload the
dispenser 70 without detaching the dispenser 70 from its position
on the user's body.
[0100] FIGS. 14 and 15 illustrate the drive pack 88 of the
connector dispenser 70. The actuator of the 76 of the dispenser is
attached to a link of the chain 90 within the drive pack 88 so that
movement of the actuator 76 along actuator path 78 causes rotation
of the chain 90 along its path within the drive pack 88. Rotation
of the chain 90 in turn causes rotation of meter roller drive
member 118 and take-up roll drive member 120. As described above,
rotation of these drive members 118, 120 and their associated drive
rollers 96, 98 causes the movement of the release material 104
within the dispenser 70. One or both of the drive members may
utilize a ratcheting member to ensure that the drive member rotates
only in one direction, i.e. the direction corresponding to forward
movement of the release material 104 along its path within the
dispenser 70. The drive members 118, 120 may attach to their
respective rollers 96, 98 in any suitable way. For example, the
drive members may have six point hex profiles that mate with twelve
point hex sockets on the rollers. This six point to twelve point
connection facilitates alignment of these components together
during assembly or during repositioning of a cover of the dispenser
70 after reloading.
[0101] Also, as the chain moves with the movement of the actuator,
spring drive members 122 rotate causing a spring (not shown) inside
spring casing 100 to coil and retain energy. After the user moves
the actuator 76 from its starting position to its finishing
position and releases his hand from the actuator, the spring
uncoils causing the chain 90 to rotate in the opposite direction
and thus causing the attached actuator 76 to return to its starting
position along path 78. Tensioning device 124 keeps the chain 90
secure in its path within drive pack 88. Casing 126 encases the
internal parts of the drive pack 88.
[0102] Several alternative dispenser designs are possible. For
instance, the dispenser may be altered for a variety of locations.
In addition to being secured to a user's belt and leg, a dispenser
may be strapped between the user's knees, mounted to the user's arm
or wrist, warn as a backpack, strapped across a user's shoulders,
or attached to, secured to, hung off, or touching any suitable part
of the user's anatomy. Typically, the location of the dispenser
will provide the user convenient access to the connectors being
dispensed.
[0103] Alternatively, the dispenser may be used separately from the
user's anatomy. For example, the dispenser may rest on the floor or
may be attached to a kneeler upon which the user kneels. The
dispenser may hang from the ceiling or walls or may be attached to
a zip line. The dispenser may also be part of or include some or
all of the packaging in which the dispenser is shipped. As other
alternative, the dispenser may dispense more than one connector at
a time or may dispense a grid of connected dispensers.
[0104] The release of the connector from the release material may
also be accomplished by alternative means than those described
above. In addition to causing release by passing the release
material around a sharp bend, a variety of other mechanisms are
contemplated. For example, release may be triggered by the user
grasping a connector and removing it from the release material. In
such cases the dispenser may dispense the release material with the
connector attached for the user to remove. For example, the
dispenser may contain a stack of fan folded release material having
one connector on each folded portion. An opening in such a
dispenser allows a user to grasp and remove release material
containing a connector and then remove the connector and discard
the release material.
[0105] As another example, a dispenser may have a continuous roll
of connectors without any release material. Such a dispenser may
have cutting member near the opening to break-of a predetermined or
user-determined amount of the connector roll for use as an
individual connector. The backing of a roll of connectors that is
rolled without release material as a backing may have a release
coating.
[0106] As another example, connectors may be stacked within a
dispenser individually, such that each connector has release
material covering all or a portion of its adhesive side, so that it
will not stick to the other connectors in the stack. The release
material may have a weak adhesive on it so that the adjacent
connectors in the stack are held together in a stack (i.e. the weak
adhesive removeably sticks to the non-adhesive side of adjacent
tiles).
[0107] As yet another alternative, the connectors may be stacked
within the dispenser so that the adhesive side of each connector
attaches to the adjacent connector. For example, a siliconated or
polyflorinated release coating such as an acrylic, polyolefin,
polyamide, or polyester may be applied to the non-adhesive side of
each tile so that the adhesive sides of adjacent tiles may be
removeably attached to the non-adhesive sides.
[0108] Stacks of connectors may be used with or without a
dispenser. In some cases, it may be convenient for an installer to
simply hold a stack of connectors removing one connector at a time
for use. The connectors in the stack may be attached in a variety
of ways such as those described above.
[0109] A dispenser of the present invention may also be configured
to dispense connectors directly onto the carpet tile without a user
touching the connector. For example, the dispenser may have a
corner into which a carpet tile corner may be placed. Once the
carpet tile is in place, the dispenser is activated by the user or
automatically by sensing the presence of the tile to dispense a
connector on the tile corner. A similar design may be used to
directly attach a connector to the edge (rather than corner) of a
carpet tile. Alternatively, the dispenser may be designed to roll
under a carpet tile corner as the carpet tile is resting on the
floor. Once in the proper position, the dispenser dispenses a
connector directly onto the carpet tile. The rolling action may
also cause the dispenser to eject a connector.
[0110] The dispenser of the present invention may also be
configured to advance release material holding connectors in a
variety of ways. In addition to an actuator that the user controls,
the advancement of the release material may be controlled by the
user pulling on the release material, the user pulling on the
connector, an electric motor, user motion (e.g., the user rocking
side to side on a kneeler), or by any other suitable technique or
device.
[0111] A dispenser according to the present invention will
typically, but not always, dispense connectors in an orientation
convenient to the user or carpet tile installer. Preferably, the
connectors will be dispensed adhesive side up so that the user is
not required to flip or rotate the connector before applying or
positioning it. The dispenser may also have a counter and display
for tracking and displaying the number of connectors remaining on
the release material. The dispenser may have an opening so that a
user can see the remaining connectors held within.
[0112] In another embodiment of this invention, the release
material 26 may be omitted entirely. Rather, the connectors 20 can
be stacked on top of each other, with the adhesive layer 24 of one
connector 20 contacting the film 22 of the connector 20 positioned
above it in the stack. The installer then simply peels a connector
20 from the stack during installation.
[0113] In one method of installing tiles using the connectors, a
first tile is placed on the floor at a position determined by
conventional tile installation methods. A connector 20 is peeled
from the release layer 26 (or from a stack of connectors 20) and
positioned so that the adhesive layer 24 faces upward away from the
underlying floor. The connector 20 is positioned so that only a
portion of the adhesive layer 24 adheres to the underside of the
tile, leaving the remainder of the connector 20 extending from the
underside of the tile. A tile or tiles are then positioned adjacent
the first tile so that a portion of the connector 20 adheres to the
adjacent tile(s). In this way, the connector spans the adjacent
edge(s) of the adjacent tile(s).
[0114] Any number of connectors 20 may be used to connect adjacent
tiles in an installation. However, to create a stable floor
covering, the connectors need not be positioned along the entirety
of the adjacent tile edges nor even across all adjacent tile edges.
Rather, unlike adhesive tape that has been used to secure adjacent
tiles together along the entirety of adjacent tile edges, the
connectors 20 of this invention need only extend along a very
limited length of the adjacent edges. For example, the tiles of a
floor covering installation where only 5%-10% of adjacent tile
edges are stabilized with connectors 20 have been found to exhibit
planar stability (measured by the cupping and/or curling of the
tiles) and dimensional stability (measured by the skewing of the
tiles), as well as the ability to retain their relative positions
in the installation when subjected to foot traffic, rolling
traffic, and stresses applied during cleaning and maintenance.
[0115] FIG. 5 shows one embodiment of a conventional installation
(i.e., in aligned columns and rows) of tiles. For ease of
discussion, the positioning of the connectors is discussed relative
to a basic unit 40 of four tiles 41-44, as shown and arranged in
FIG. 6. Tiles 41-44 are preferably connected with a central
connector 46 at the corners where they intersect. Moreover, the
corner of each tile diagonal from the center connector 46 is also
connected to adjacent tiles with a connector 20. In this way, only
a total of two tile connectors (the center connector 46 plus a
quarter of a connector at each of the four diagonal tile corners)
need be used to install the basic unit 40 of four tiles 41-44.
Breaking this down even further, each of the four tiles 41-44,
draws its stability from, on average, only one half of the surface
area of a connector.
[0116] FIG. 7 illustrates possible connector placement in a
brick-laid tile installation (or ashlar installation if FIG. 7 is
rotated ninety degrees). For ease of discussion, the preferable
positioning of the connectors 20 is discussed relative to a basic
unit 60 of four tiles 61-64, as shown and arranged in FIG. 8. As
with tiles 41-44, a total of only two tile connectors (1/2 of a
connector per each tile) need be used to install the basic unit 60
of four tiles 61-64.
[0117] FIGS. 5-8 illustrate a few of only countless connector
placement possibilities for installing tiles. Connectors 20 may be
positioned at any location between adjacent tiles, and thus any
given tile in the installation may contact a portion of as few as
one connector and as many as feasible given the size of the tile
and of the connectors 20. In addition to placement at the corners
of intersecting tiles, connectors 20 may be positioned to span the
adjacent edges of only two tiles. Moreover, different shaped or
sized connectors 20 may be useful in a single installation. For
example, in addition to the rectangular connectors shown in FIG. 5,
triangular-shaped connectors may be useful at the border of an
installation, such as where the tiles abut a wall.
[0118] In addition to on-site placement of the connectors 20, it is
also possible to pre-position the connectors 20 at desired
locations on the tiles during manufacture. For example, the release
material 26 on the connectors 20 may be perforated. During
manufacture, a portion of the release material 26 can thus be
removed along the perforation to expose a portion of the adhesive
layer 24. That portion of the connector 20 can then be adhered to
the underside of the edge of a tile 50 as discussed above (see FIG.
9). The adhesive on the remainder of the connector 20 is still
protected by the remaining release material 26. To prevent the
connector 20, which extends from tile 50, from interfering with
packaging of tile 50 for shipment, it may be preferable to bend the
connector 20 along the perforation back (in direction A) so that
the underside of the connector 20 is flush with itself. During
installation, the installer need only extend the connector 20 from
the edge of tile 50, remove the remaining release layer 26 and
install the tiles 50 as discussed above.
[0119] Because the tiles are not attached to the floor, they need
not be placed directly on an underlying flooring surface. Rather,
the connectors 20 of this invention work equally well with tiles
positioned on an intermediate substrate positioned between the
tiles and the floor. Such intermediate substrates can serve to
protect the floor from damage, such as might be caused by liquids
spilled on the tiles that escape through the tile seams.
Additionally, the intermediate substrates can serve as a barrier to
moisture present in the existing floor and thereby eliminate the
need for sealants and barrier coatings. Because the intermediate
substrate does not need to be adhered to the flooring surface, it
is removable with minimal cleanup and replacement cost.
[0120] One embodiment of an intermediate substrate is a sheet or
film 202 that may be positioned on the floor 206 prior to tile
installation and thus between the floor 206 and the tiles 200, as
shown in FIG. 16. The film 202 can be made from any suitable
material and is preferably, but not necessarily, non-porous and
non-permeable to moisture. In addition, the film 202 preferably is
insensitive to highly alkaline conditions and preferably does not
emit volatile organic compounds in excess of 350
micrograms/cm.sup.2. The film 202 is preferably, but not
necessarily, flexible to conform with irregularities in the floor
206. The film 202 can be made from any number of materials,
including polymeric materials such as polyethylene, polypropylene,
or PVC. A suitable film 202 can also contain, but is not limited
to, certain polyolefins, polyesters, polyamides, and
cellulose-based polymers.
[0121] Although the film 202 can be of any thickness, in one
embodiment the thickness is between about 1/1000 inch to about
40/1000 inch and more preferably between about 2/1000 inch to about
10/1000 inch. Preferably, but not necessarily, the underlayment
film has antimicrobial properties in its natural state, but if not,
the film can be, but does not have to be, treated with
antimicrobial chemical agents to prevent the growth of bacteria or
other microbiological organisms. Additionally, the flammability of
the underlayment film will preferably not have a negative effect on
the flammability or smoke generating rating of the tile.
[0122] It may be desirable to increase the coefficient of friction
on at least one side of the film 202 to impart anti-skid properties
to the film 202. Preferably, but not necessarily, the coefficient
of friction of at least one side of the film 202 is greater than
0.55. For example, a side of the film 202 may be manufactured from
resin materials with tacky surface characteristics. For example,
the film 202 can have a relatively smooth side (side 208 in FIG.
16) and an opposite side with a higher coefficient of friction
(side 206 in FIG. 16). The film 202 can be positioned so that side
206 is positioned towards the floor 204. When so positioned,
friction between the floor 204 and side 206 of the film 202
prevents the film 202 (and thus the carpet or carpet tiles
positioned thereon) from moving relative to the floor 204, even
with heavy foot traffic or other movement on the above-positioned
tiles. While side 208 may also be provided with surface
characteristics to increase its coefficient of friction, it is
preferably relatively smooth so as to prevent the film 202 from
sticking to the tile 200 or other underlayment.
[0123] In an alternative embodiment, an intermediate substrate
between the tiles and the floor is a cushion or foam pad positioned
on the floor before tile installation. The cushion provides comfort
underfoot and can eliminate the need to use cushion back carpet
tiles. Rather, hardback tiles can simply be installed on an
underlying cushion pad. Additionally, the cushion serves as a
barrier to moisture present in the existing floor.
[0124] The cushion can be made from any natural or synthetic
material, or blends thereof, that provides a cushioning effect,
such as compressive, resilient composites. For example, the cushion
can be made from foam, rubber, cork, and woven, felted, and
nonwoven fabrics. The cushion can be made from virgin or recycled
polymeric material and is preferably, but not necessarily, made
from 100% recycled materials. If the cushion underlayment is a foam
material, the foam can be open or closed cell foam and can be made
from any suitable polymer, including but not limited to,
polyvinylchloride, polyurethane, and polyolefins. The woven,
nonwoven, or felted cushions may be made from natural or synthetic
materials, including, but not limited to, wool, cotton, flax, hemp,
kenaf, sugarcane, and other naturally occurring cellulosic
derivatives or polyamides, polyesters, polyolefins, and blends
thereof. If non-woven, the cushion can be formed by needle punching
with or without bonding agents or by a spun-bonding process. If
woven, the cushion can be formed via weaving, knitting, etc. The
cushion can be reinforced with fibers (e.g., fiberglass) for
dimensional stability and added tear strength. While not necessary,
the cushion preferably has the same characteristics as the film 202
(e.g., moisture resistant, low VOC content, conforms to floor,
etc.)
[0125] Depending on the moisture resistant properties of the
cushion, it may be desirable to install the cushion with the film
202. In the embodiment of FIG. 17, the film 202 is placed directly
on the floor surface 204. A cushion 210 is then placed on top of
the film 202 and the tile 200 is placed on top of the cushion 210.
Adjacent tiles can be held in place using the connectors 20, which
can optionally be conductive connectors 150, as described
above.
[0126] In another embodiment shown in FIG. 18, the cushion 210 is
used without the film 202. In this embodiment, the cushion 210 is
placed directly on the floor surface 204. The tile 200 is then
placed on top of the cushion 210. Adjacent tiles then can be
secured together with connectors 20 or conductive connectors 150,
as described above. As with film 202, it may be desirable to impart
a higher coefficient of friction to at least one side of the
cushion 210 to prevent relative movement between the cushion and
film (see FIG. 17) or cushion and floor (see FIG. 18).
[0127] The cushion 210 can be of any thickness. It is preferable,
however, that the cushion's thickness does not exceed the thickness
of the tile backing so that, when compressed, the cushion does not
compress below the tile backing so as to cause a tripping
hazard.
[0128] Regardless of the type of intermediate substrate used (if
any), in one embodiment all of tiles placed atop the intermediate
substrate are connected together using the connectors disclosed
herein. In this way, none of the layers in the installation are
connected to any other layer in the installation (e.g., the
intermediate substrate is not connected to the floor and the
carpeting or tiles are not connected of the intermediate
substrate). In this way, the flooring may be easily removed without
requiring clean-up and preparation before installation a subsequent
floorcovering.
[0129] Yet another embodiment of an intermediate substrate is a
cushion composite particularly well-suited for installing new
carpet or carpet tiles over existing wall-to-wall carpeting or
carpet tiles without having to remove the existing carpeting or
carpet tiles.
[0130] One embodiment of a cushion composite 216 is illustrated in
FIG. 19. In the embodiment shown in FIG. 19, the cushion composite
216 includes a semi-rigid layer 220 attached to a cushion 226.
"Semi-rigid" means any structure that has some flexibility such
that it can bend to some degree. Cushion 226 may have, but does not
have to have, characteristics similar to those disclosed above
relative to cushion 210. The semi-rigid layer 220 may be made out
of any material. A synthetic polymeric material, such as
polyolefin, polyamide, or polyester, may be particularly suitable
in this application.
[0131] The semi-rigid layer 220 has a first side 222 and a second
side 224. The second side 224 is provided with gripping components,
such as teeth 218, that project from second side 224. While the
teeth 218 are disclosed as being integrally-formed with the
semi-rigid layer 220, they need not be. Rather, the gripping
components may be fixed in any way (such as with adhesive,
fasteners, clips, or any other chemical or mechanical fixation
means) to the second side 224 of the semi-rigid layer 220.
[0132] The first side 222 is attached to cushion 226. If cushion
226 is pre-formed, the semi-rigid layer 220 can be molded onto the
pre-formed cushion 226. Alternatively, if a foam material is used
to make the cushion 226, the foam can be deposited directly onto
the first side 222 of a pre-formed semi-rigid layer 220.
Alternatively, the cushion 226 and semi-rigid layer 220 may each be
pre-formed and subsequently adhered or otherwise affixed
together.
[0133] As shown in the embodiment of FIG. 20, the cushion composite
216 can be placed on top of existing carpet or tiles 212.
Preferably, the cushion composite 216 is positioned so that the
gripping components 218 penetrate into a portion of the existing
carpet or tiles 212 to prevent relative movement between the
cushion composite 216 and existing carpet or tile 212. The new
carpet or carpet tile 214 is then placed on top of the cushion
226.
[0134] Use of the cushion composite 216 allows new carpet or carpet
tile to be positioned over existing carpet or tiles without first
removing the existing carpet or tiles. The new carpet tiles can
then be secured together with the connectors 20 or conductive
connectors 150, as described above. In the embodiment shown in FIG.
20, none of the layers (i.e., the existing carpet or tile 212, the
cushion composite 216, and the new carpet or carpet tile 214) are
affixed to each other. Thus, the installation of new tiles need not
be permanent but rather can be easily removed. Moreover, the
gripping components 218 are preferably, but not necessarily,
designed so as not to damage the face of the existing carpet or
tiles. Thus, an installation of new tiles can be removed without
altering the appearance or usability of the existing carpet or
tiles.
[0135] The connectors of this invention improve upon current tile
installation systems and methods. The connectors use both less
material and cheaper materials than traditional installation
systems. Moreover, use of the connectors significantly reduces tile
installation time (by as much as 60% of the time for adhesive
systems) by obviating the need to prep a floor prior to
installation. Rather than applying a layer of adhesive to the floor
and then retracing his steps to position the tiles on the adhesive
layer, with the connectors, the installer positions and secures as
he goes. Moreover, given the releasable adhesive used on the
connectors and the limited surface area of the tiles that contacts
the connectors, the tiles can easily be re-positioned if necessary.
Furthermore, because the tiles do not interact with the underlying
floor, they are easily removable from the floor and leave the
underlying floor pristine upon such removal. Consequently, the
floor does not require refinishing before it is recovered with
another floorcovering.
[0136] The embodiment described above is illustrative and
non-limiting. Many variations of the structures illustrated in the
drawings and the materials described above are possible and within
the scope of this invention as defined in the claims.
* * * * *